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Drilling in Salt Formations and Rate of Penetration Modelling

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Drilling in Salt Formations and Rate of Penetration Modelling Drilling in Salt Formations and Rate of Penetration Modelling Mats Håpnes Petroleum Geoscience and Engineering Submission date: June 2014 Supervisor: John-Morten Godhavn, IPT Norwegian University of Science and Technology Department of Petroleum Engineering and Applied Geophysics NORWEGIAN UNIVERSITY OF SCIENCE AND TECHNOLOGY Abstract Faculty of Engineering Science and Technology Department of Petroleum Engineering and Applied Geophysics Master of Science Drilling in Salt Formations and Rate of Penetration Modelling by Mats Håpnes As the industrialization of the world is growing, both energy consumption and demand are steadily increasing. Hydrocarbons have been an important energy provider for several decades, but the production from mature oil and gas producers is now declining. In order to meet this rise in energy demand, new hydrocarbon deposits must be found and produced. Because large oil and gas reservoirs are associated with salt formations, this may be an important energy source for the future. Salt’s low permeability and ability to deform under stress and temperature, makes it an ideal hydrocarbon-trap. The initial objective of this thesis was to establish which challenges are related to drilling for pre-salt hydrocarbons, and propose solutions for how to overcome these challenges. When drilling towards these oil and gas reservoirs, the first problems may occur already in the formations above the salt structures. The density of salt does not increase with burial depth. When its density becomes lower than of the surrounding formations, salt will start to migrate and push through the overlying rocks. Due to the combined effect of compaction disequilibrium and salt tectonics, complex stress patterns can be created in the formations surrounding the salt structures. This may lead to many hazardous scenarios, created by rubble zones and recumbent beds. When drilling inside salt formations, it is salt’s ability to creep and flow that may cause problems. Salt flow may cause borehole deformation ii that impedes with the drilling and casing operations. When a wellbore has been drilled, salt can creep into the removed rock volume. This may cause situations such as stuck-pipe, hole instability, and high levels of shock and vibration when drilling. Salt flow is a positive function of time, so minimizing the time factor will decrease the possibility of salt flow related problems. One of the measures to minimize exposure time is to perform drilling operations quickly. Hence, a high rate of penetration (ROP) is beneficial when drilling in salt. As part of proposing solutions to the drilling challenges in salt, two new drillbit technologies have been evaluated. These bits may be beneficial in order to over- come many of the problems related to salt drilling. Based on the results obtained in previous studies, these bits are capable of reducing the shock and vibration levels while drilling. This is because these bits are able to drill smoother than conventional PDC bits. Further, the reduced shock and vibration levels will al- low an increase in WOB and rotary speed. Based on previous studies, these are the two of the most important parameters to ROP. Thus, these two new drillbit technologies might be able to increase ROP when drilling in salt. Another goal for this thesis was to establish which parameters have the most effect on ROP when drilling in salt formations. Knowing this could help minimize the challenges faced due to salt creep and flow. Therefore, a modelling attempt was performed using Bourgoyne and Young’s ROP model. This model uses multiple linear regressions to calculate a straight line that best fits the data used in the model. In this attempt, data acquired from a well drilled in salt formation was used. Due to lack of variation in the drilling data, several parameters had to be discarded from the model in order to obtain physically meaningful results. This led to only three variables being used in the model. This was weight on bit (WOB), rotary speed of the drillstring, and jet impact force. It was found that the parameter that had most effect on ROP in salt was WOB, followed by rotary speed, and last, jet impact force. iii NORGES TEKNISK-NATURVITENSKAPELIGE UNIVERSITET Abstrakt - Norsk Fakultet for Ingeniørvitenskap og Teknologi Institutt for Petroleumsteknologi og Anvendt Geofysikk Master i Teknologi/Sivilingeniør Boring i saltformasjoner og modellering av penetrasjonsrate av Mats Håpnes Ettersom industrialiseringen av verden vokser, er både energiforbruket og -etterspørselen stadig økende. Hydrokarboner har vært en viktig energikilde i flere tiår, men pro- duksjonen fra modne olje- og gassprodusenter er nå avtagende. For å møte denne voksende energietterspørselen må nye hydrokarbonforekomster bli funnet og pro- dusert. Ettersom store olje- og gassreservoarer er tilknyttet saltformasjoner, kan utvinning av hydrokarboner i disse områdene være en viktig energileverandør for fremtiden. Saltets lave permeabilitet og evne til å deformere under trykk og tem- peratur, gjør det til en ideell hydrokarbonfelle. Et av målene med denne avhandlingen var å kartlegge hvilke utfordringer som kan oppstå ved boring etter pre-salt hydrokarboner, samt foreslå løsninger for hvordan disse kan overkommes. Ved boring etter disse olje- og gassreservoarene kan det oppstå problemer allerede i formasjonene over saltstrukturene. Tettheten av salt øker ikke med overdekningdybde. Når dens tetthet blir lavere enn de omkring- liggende formasjoner, kan salt migrere og presse seg gjennom de overliggende bergartene. På grunn av den kombinerte effekten av ubalanse i kompasjon og salttektonikk, kan komplekse spenningsmønstre oppstå i formasjoner som omgir saltstrukturer. Dette kan føre til mange farlige situasjoner, forårsaket av soner med knust stein og foldede lagdelinger. Ved boring i saltformasjoner er det saltets evne til å flyte som kan forårsake problemer. Flytende salt kan føre til deformasjon iv av borehullet, noe som kan vanskeliggjøre bore- og foringsrøroperasjoner. Når en brønn er boret kan salt flyte inn og erstatte det fjernede bergartsvolumet. Dette kan føre til situasjoner som fastklemt borestreng, hullustabilitet, og høye nivåer av støt og vibrasjoner under boring. Saltstrømming er positiv korrelert med tid, slik at minimering av tidsfaktoren vil redusere muligheten for saltstrømmingsre- laterte problemer. Ett av tiltakene for å minimalisere eksponeringstiden er å utføre boreoperasjoner raskt. Derfor er en høy penetrasjonsrate gunstig ved boring i salt. Som et ledd i å foreslå løsninger på utfordringene ved boring i salt har to nye borekroneteknologier blitt evaluert. Disse kan være fordelaktige for å overkomme mange av utfordringene knyttet til boring i salt. Basert på resultatene oppnådd i tidligere studier, er disse borekronene i stand til å redusere støt- og vibrasjon- snivået under boring. Dette skyldes at disse borekronene er i stand til å bore jevnere enn konvensjonelle PDC-borekroner. Det reduserte støt- og vibrasjon- snivået tillater en økning i vekt på borekronen og rotasjonshastighet. Basert på tidligere studier er dette to av de viktigste parametrene til penetrasjonsraten. Derfor kan disse to nye borekroneteknologiene øke penetrasjonsraten ved boring i salt. Et annet mål for denne avhandlingen var å avdekke hvilke parametere som har mest effekt på penetrasjonsraten ved boring i saltformasjoner. Kunnskap om dette kan bidra til å redusere utfordringene knyttet til saltflyt. Dette ble gjort ved å gjennomføre et modelleringsforsøk ved å benytte Bourgoyne og Youngs pene- trasjonsratemodell. Denne modellen bruker flere lineære regresjoner for å beregne en rett linje som passer best til de dataene som brukes i modellen. I dette forsøket ble det benyttet data fra en brønn boret i saltformasjon. På grunn av man- glende variasjon i boredataene måtte flere parametere forkastes fra modellen for å oppnå fysisk meningsfulle resultater. Dette førte til at kun tre variabler ble brukt i modellen. Disse var vekt på borekronen, rotasjonshastighet på bore- strengen og stråleslagkraft. Parameteren som viste seg å ha størst påvirkning på penetrasjonsraten var vekt på borekronen, etterfulgt av rotasjonshastigheten og deretter stråleslagkraft. Acknowledgements I want to thank my supervisor John-Morten Godhavn for providing me with feed- back, remarks and useful comment throughout my learning process of this master thesis. I would also like to thank Espen Hauge for his assistance in this project. v Contents Abstracti Abstrakt - Norsk iii Acknowledgementsv Contents vi List of Figures xi List of Tables xv Abbreviations xvii Symbols xix 1 Introduction1 2 Background Theory5 2.1 Origin and Characteristics of Salt...................5 2.1.1 In-Situ Conditions.......................8 2.2 Salt Domes...............................9 2.2.1 Physical Characteristics of Salt Domes............ 11 2.2.2 Origin of Salt Domes...................... 13 2.2.3 Distribution of Salt Structures................. 14 2.2.4 Economic Significance of Salt Domes............. 14 2.3 Drilling in Salt............................. 15 2.3.1 Wellbore Stability........................ 15 2.3.2 Drilling Fluids.......................... 16 2.3.3 Cementing............................ 17 2.3.4 Casing Design.......................... 18 2.3.5 Directional Control....................... 18 3 Geomechanical Considerations for Salt Drilling 21 vii Contents viii 3.1 Through-, Sub- and Near-Salt Drilling Hazards........... 21 3.2 Deformation Styles Adjacent to Salt.................. 26 3.2.1 Diapirism and the Down-Building
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